Two-Layer Tissue Feeding Unit with Segmented Cutting
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Solution Overview
Problem
Existing feeding units for tissue converting machines are unable to continuously feed two-layer tissue webs without stopping the machine, and they fail to ensure precise alignment of the tissue layers during the joining process.
Innovation Solution
A feeding unit with support means for two-layer reels, cutting means that cut the tissue web along spaced cut lines, and joining means that attach new layers to the corresponding layers of the used reel, ensuring continuous operation and precise alignment by using a first cutting member and a pair of second cutting members with separating elements to maintain layer detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tissue layers are separated from each other as they move through the feeding unit, then the feeding unit can process multi-layer tissue webs, but the tissue layers cannot be precisely aligned with each other
Solution Approach 1:
The cutting means is divided into multiple independent cutting members (first cutting member for inner layer, second cutting member for outer layer) that can independently cut different layers at different positions, enabling precise control of each layer while maintaining overall alignment
Solution Approach 2:
Separating elements are introduced as intermediary components that temporarily detach the outer layer from the inner layer during the cutting process, allowing independent cutting of each layer while ensuring they remain aligned through the separating element's guidance
2Reliability
If the machine stops to replace spent tissue reels, then the joining process can be performed, but continuous feeding cannot be maintained
Solution Approach 1:
The tissue web from the reserve reel is preliminarily positioned and aligned with the tissue web from the reel in use before the actual joining operation, allowing the cutting and joining process to occur while the machine continues to feed tissue to the converting section
Solution Approach 2:
The feeding unit maintains continuous tissue web supply to the converting machine during the reel replacement process by coordinating the cutting of the spent reel's web with the simultaneous feeding of the reserve reel's web, eliminating any interruption in the converting operation
Data Source
AI summary
The feeding unit (10) comprises: support means (12) for rotatably supporting a first reel (R1) of two-layer tissue web and a second reel (R2) of two-layer tissue web about respective axes of rotation (x1, x2); cutting means (32, 42) for cutting the two layers (L1_1, L2_1) of the tissue web (W1) of the reel (R1) in use, the cutting means (32, 42) being configured to cut the two layers (L1_1, L2_1) of the tissue web (W1) along two cut lines spaced apart from each other in the longitudinal direction of the web (W1); joining means (44_1, 44_2) for joining each of the two layers (L1_2, L2_2) of the tissue web (W2) of the other reel (R2) of said first and second reels (R1, R2), and precisely of the new reel, to a respective layer (L1_1, L2_1) of the tissue web (W1) of the reel (R1) in use; and tissue web accumulation means (30) for accumulating a given amount of web (W1) downstream of the cutting means (32, 42) and the joining means (44_1, 44_2) so as to ensure the feeding of the machine with the tissue web (W1) while the portion of tissue web (W1) on which the cutting means (32, 42) and the joining means (44_1, 44_2) act is kept temporarily still to allow the cutting of the two layers (L1_1, L2_1) of the tissue web (W1) in use and the joining of the latter with the two layers (L2_2, L2_2) of the new tissue web (W2).